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methods, pipe freeze protection, overheat protection, immersed heat exchanger modeling and testing methods, and polymer heat exchanger materials life and testing. Fig. 1. Schematic of DEG/SE glazed ICS Fig. 2. DEG/SE glazed ICS on field test Fig. 3. DEG/SE unglazed ICS prototype Fig. 4. Two thermosiphon prototypes on test at FAFCO 2. Technical Approach With the cost-reduction objective, the technical strategy is to: (1) use low-cost polymer materials and manufacturing technology; (2) simplify system designs and installation, exploiting the formability of polymers to reduce part count and to provide molded-in joining features. The two teams, DEG/SE and FAFCO, are subcontracted to develop these systems. The DEG/SE team has been installing prototypes, seeking certification from the Solar Rating and Certification Corporation (SRCC) and addressing tank leakage issues seen in production and in field testing (as described in SunCache Residential Solar Water Heating System – Phase VI). They also developed a less- expensive, lower-performing unglazed version of the unit, as in Fig. 3. The FAFCO team changed system type in FY 2004 from integral collector storage (ICS) to flat plate, based on the company’s polymer swimming pool collector. They developed full-scale prototypes, addressing issues with overheating and freezing. FAFCO plans both a thermosiphon system and a direct active system (as described in the 2005 Solar Program Review Meeting paper Innovative Low-cost Polymer Solar Domestic Water Heater). With the polymer strategy comes new opportunities and new problems. The key problem to be addressed is materials durability under harsh environmental stresses and high temperatures. A minimum lifetime for polymer solar systems was set at 10 years; the desired lifetime, however, is at least 20 years. These criteria lead to the need for sophisticated and capital-equipment-intensive accelerated testing to identify appropriate Solar Thermal R&D Solar Heating and Lighting 131PDF Image | DOE Solar Energy Technologies Program
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